Decking panel apparatus, system and method

ABSTRACT

A decking panel apparatus and system and method of installing the same. The decking panel apparatus is typically a planar polygonal body having an upper surface and a lower surface. The upper surface typically includes one or more elongated channels thereby simulating the appearance of individual deck boards as with conventional decks, the channels including bridge tabs having through holes. The body further includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels. The parallel sides have a tapered profile and half bridge tabs having through holes. In another embodiment, the parallel sides include an elongated slot that can receive a separate fastener that fits into the elongated slot and an elongated slot of an adjacent panel. The fastener includes a screw hole for connection into the joists.

Priority based on U.S. Provisional Patent Application Ser. No. 60/673,401, filed Apr. 21, 2005, and entitled, “Decking Panel Apparatus and System” is claimed.

BACKGROUND

I. Field of the Invention

The present invention relates generally to the field of construction and more particularly to a decking panel apparatus and system and method of installing the same.

II. Description of the Related Art

Present construction techniques, typically for decks, use conventional lumber and composite boards. The boards are placed over joists that typically have standard spacing. Lumber has many disadvantages primarily because wood can warp, rot and otherwise requires high maintenance to keep it in good operational condition. Furthermore, lumber typically comes in elongated boards up to sixteen feet that can take a full day to place. In many applications, composite boards are used in lieu of lumber. Composite typically includes a mixture of plastic and sawdust pressed together. While composite offers several advantages over conventional lumber, composite can have a large degree of contraction and expansion which is dependent on weather and temperature conditions. Composite, like lumber, also comes in elongated boards. For a sixteen foot board of composite, expansion and contraction of up to one quarter of an inch can occur which can cause damage to the structure and is otherwise displeasing aesthetically because it can cause a visible offset appearance. Composite can also take a full day to install. In addition, although composite offers the advantage of including pre-drilled holes for screws, the screws typically remain visible after installation. Furthermore, since the holes are pre-drilled, any discrepancies in the joist placement can results in misaligned screw holes. Expansion and contraction can also misalign the screw holes. In addition, since both lumber and composite are typically manufactured in elongated boards, long flatbed trucks are typically required for shipping.

SUMMARY

In general, the invention features a decking panel apparatus and system and method of installing the same. The decking panel apparatus is typically a planar polygonal body having an upper surface and a lower surface. The lower surface is typically uniformly flat. The upper surface typically includes one or more elongated channels thereby simulating the appearance of individual deck boards as with conventional decks. Each channel therefore is cut through the entire body to simulate the spacing between deck boards. However, there is a bridge tab on either side of each channel and recessed into the channel by a distance typically half way down, although other distances are contemplated. Each bridge tab connects the individual boards together and includes a through hole to receive installation screws for connection to deck joists. The body further includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels. The parallel sides have a profile that tapers from the upper surface toward the lower surface. At the lower surface, each side includes a half bridge tab that aligns with a corresponding offset half bridge tab of an adjacent panel such that a full bridge tab is formed between adjacent panels. The half tabs include a screw hole. In another embodiment, the parallel sides are not tapered but include an elongated slot that can receive a separate fastener that fits into the elongated slot and an elongated slot of an adjacent panel. The fastener includes a screw hole for connection into the joists. The separate fastener thus acts as a bridge tab for adjacent panels.

In general, in one aspect, the invention features a decking panel apparatus, including a planar body having an upper surface and a lower surface, one or more elongated channels, each channel having an elongated through slot along a portion of the channel and a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels.

In one implementation, the parallel sides have a profile that tapers from the upper surface toward the lower surface.

In another implementation, the apparatus further includes a half bridge tab adjacent the perpendicular sides.

In another implementation, the apparatus further includes a screw hole on the bridge tabs and on the half bridge tabs.

In another implementation, the parallel sides include an elongated slot adjacent the lower surface.

In another aspect, the invention features a decking panel system, including one or more adjacently placed panels, the panels each having a planar body having an upper surface and a lower surface, one or more elongated channels, each channel having an elongated through slot along a portion of the channel, a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels and a half bridge tab adjacent the perpendicular sides, wherein the half bridge tabs of adjacent panels align with another when the panels are placed side by side, thereby simulating a bridge tab.

In another aspect, the invention features a decking panel apparatus, including a planar body having an upper surface and a lower surface, one or more elongated channels, each channel having an elongated through slot along a portion of the channel and a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels.

In one implementation, the parallel sides parallel to the channels have a profile that tapers from the upper surface toward the lower surface.

In another implementation, the apparatus further includes a half bridge tab adjacent the perpendicular sides.

In another implementation, the apparatus further includes a through-hole disposed on the bridge tabs.

In another implementation, the apparatus further includes a through-hole disposed on the half bridge tabs.

In another implementation, the parallel sides include an elongated slot adjacent the lower surface.

In another implementation, the parallel side taper from the upper surface to the lower surface and terminate in a shelf.

In another implementation, the parallel sides parallel to the channels are disposed generally vertical to the upper and lower surfaces.

In another implementation, the apparatus further includes an elongated slot disposed along parallel sides, the elongated slot being parallel to the channels.

In another implementation, the apparatus further includes a fastener having a head and shaft for disposition into the elongated slot.

In another aspect, the invention features a decking panel system, including one or more adjacently placed panels, the panels each having a planar body having an upper surface and a lower surface, one or more elongated channels, each channel having an elongated through slot along a portion of the channel, a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels and means for coupling to an adjacent decking panel and disposed adjacent the perpendicular sides.

In one implementation, the means for coupling to an adjacent decking panel, comprises a half bridge tab adjacent the perpendicular sides, wherein the half bridge tabs of adjacent panels align with another when the panels are placed side by side, thereby simulating a bridge tab.

In another implementation, the means for coupling to an adjacent decking panel includes an elongated slot disposed along parallel sides and a fastener disposed in the elongated slot.

In another implementation, the fastener includes a head and a shaft connected to the head, wherein the shaft and head for a T-configuration and wherein a portion of the head is disposed within the elongated slot.

In another aspect, the invention features a decking panel kit, including a decking panel apparatus, having elongated slots and boards in a parallel arrangement simulating a deck pattern and bridge tabs disposed within the slots and between adjacent boards connecting boards to one another.

In another implementation, the kit further includes means for coupling adjacent panels to one another.

In another implementation, the means for coupling adjacent panels comprises half bridge tabs disposed on sides of the decking panel apparatus.

In another implementation, the means for coupling adjacent panels includes an elongated slot disposed along a side of the decking panel apparatus and a fastener for interconnection to the elongated slot and to an elongated slot on an adjacent panel and for interconnection to a deck joist.

In another implementation, the fastener connects to the elongated slots via a head.

In another implementation, the fastener connects to the deck joist via a screw inserted through a through-hole disposed through the head and a shaft connected to the head.

One advantage of the invention is that overall expansion and contraction of individual panels and the overall installation is greatly reduced.

Another advantage of the invention is that the compact panels are easy to ship.

Another advantage of the invention is that the panels can be used to create unique installation patterns.

Another advantage of the invention is that installation screws are not visible after installation.

Another advantage of the invention is that installation time is greatly reduced.

Other objects, advantages and capabilities of the invention will become apparent from the following description taken in conjunction with the accompanying drawings showing the preferred embodiment of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a top view of an embodiment of a decking panel apparatus;

FIG. 2 illustrates two side views of embodiments of decking panel apparatuses;

FIG. 2A illustrates a side view and a top view of an alternate embodiment of a decking panel apparatuses;

FIG. 3 illustrates a bottom view of an embodiment of a decking panel apparatus having two adjacent decking panel apparatuses;

FIG. 4 illustrates a top view of an embodiment of decking panel apparatuses installed on deck joists;

FIG. 5 illustrates a top view of an embodiment of installed decking panel apparatuses; and

FIG. 6 illustrates a top view of an embodiment of installed decking panel apparatuses.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference numerals designate corresponding parts throughout the several figures, reference is made first to FIG. 1 that illustrates a top view of an embodiment of a decking panel apparatus 100. The decking panel apparatus 100 is typically a planar polygonal body 105 having an upper surface 106 and a lower surface 107. The lower surface 107 is typically uniformly flat. The upper surface 106 typically includes one or more elongated channels 110 thereby simulating the appearance of individual deck boards as with conventional decks. Each channel 110 therefore is cut along the entire body 105 to simulate the spacing between deck boards. However, there is a bridge tab 115 on either side of each channel 110 and recessed into the channel by a distance typically half the over-all thickness of the body 105, although other depths are contemplated.

Each bridge tab 115 typically connects the individual boards 120 to one another and each bridge tab 115 includes a through-hole 116 to receive installation screws for connection to deck joists as discussed further in the description below. The body 105 further includes two parallel sides 108 that are perpendicular to the channels and two parallel sides 109 that are parallel to the channels 110. The parallel sides 109 have a profile (discussed further in the description below) that tapers from the upper surface 106 toward the lower surface 107. At the lower surface 107, each parallel side 109 includes a half-bridge tab (125 see below) that aligns with a corresponding offset half bridge tab 125 of an adjacent panel such that a full bridge tab is formed between adjacent panels. The half tabs 125 include a through-hole 126 for interconnection with joists, similar to the through-holes 116. It is generally appreciated that in a typical embodiment, the entire apparatus 100 is a single integral piece appropriately machined to form the components as described immediately above.

FIG. 2 illustrates two side views of embodiments of decking panel apparatuses 100. As described above, the decking panel apparatus 100 is typically a planar polygonal body 105 having an upper surface 106 and a lower surface 107. The upper surface 106 includes one or more elongated channels 110 that can have a width d. A bridge tab 115 is disposed on either side of each channel 110 and recessed into the channel by a depth D typically half the total depth of the body 105, although other distances are contemplated. Each bridge tab 115 connects the individual boards 120 to one another and each bridge tab 115 typically includes a through-hole 116 to receive installation screws for connection to deck joists as discussed further in the description below. The body 105 further includes two parallel sides 108 that are perpendicular to the channels and two parallel sides 109 that are parallel to the channels 110. The parallel sides 109 have a profile that tapers from the upper surface 106 toward the lower surface 107. Typically, the tapered side terminates in a shelf 111, onto which through-holes 126 are disposed. At the lower surface 107, each parallel side 109 includes a half bridge tab 125 that aligns with a corresponding offset half bridge tab 125 of an adjacent panel such that an effective full bridge tab is formed between adjacent panels. As mentioned above, the half tabs 125 each include through-hole 126, which generally creates two through-holes 126 on the effective full bridge tab.

In another embodiment, the parallel sides 109 are not tapered as described with respect to the embodiments above. Instead, the side 109 is generally vertical and includes an elongated slot 130 disposed along the length of the side 109, and therefore generally parallel to the channels 110. In a typical embodiment, the slot 130 can receive a separate fastener 200. In general, the fastener 200 can include a head 210 and shaft 215 in a general T-orientation. Sides of the head 210 generally fit into slot 130 and into an adjacent slot on an adjacent apparatus, thereby coupling the adjacent apparatuses to one another. The fastener includes a screw hole 205 for connection into the joists. The separate fastener 200 thus acts as an effective bridge tab for adjacent panels.

FIG. 2A illustrates a side view and a top view of an alternate embodiment of a decking panel apparatus 100. Similar to as described above, the decking panel apparatus 100 is typically a planar polygonal body 105 having an upper surface 106 and a lower surface 107. The upper surface 106 includes one or more elongated channels 110 that can have a width d. A bridge tab 115 is disposed on either side of each channel 110 and recessed into the channel by a depth D typically half the total depth of the body 105, although other distances are contemplated. Each bridge tab 115 connects the individual boards 120 to one another and each bridge tab 115 typically includes a through-hole 116 to receive installation screws for connection to deck joists as discussed further in the description below. The body 105 further includes two parallel sides 108 that are perpendicular to the channels and two parallel sides 109 that are parallel to the channels 110. The parallel sides 109 have a vertical profile.

The sides 109 include an elongated slot 130 disposed along the length of the side 109, and therefore generally parallel to the channels 110. In this embodiment, the slot 130 can receive a protruding portion 117 of the bridge tab 115. The protruding portion 117 is generally the same width as the bridge tab 115 and is concealed once adjacent apparatuses 100 are interconnected as seen from the top view (protruding portion 117 shown in phantom from the top view).

FIG. 3 illustrates a bottom view of an embodiment of a decking panel apparatus 100 having two adjacent decking panel apparatuses 100A, 100B. As described above, the decking panel apparatus 100 is typically a planar polygonal body 105 having an upper surface 106 and a lower surface 107 that is generally flat. It is appreciated that the channels 110 have a through-portion or slot opening 112, which is illustrated in this bottom view. Therefore, the slot openings 112, 112A, 112B provide an aesthetic appearance that allows the apparatuses 100, 100A, 100B to appear as individual wood planks of a wooden (or composite) decks.

The bridge tab 115 is disposed on either side of each channel 110. It is appreciated that the bridge tabs 115 are an integral part of the body 105 as illustrated in this bottom view. Each bridge tab 115 connects the individual boards 120 together and each bridge tab 115 includes a through-hole 116 to receive installation screws for connection to deck joists. The body 105 further includes two parallel sides 108 that are perpendicular to the channels 110 and two parallel sides 109 that are parallel to the channels 110. In this view, it is appreciated that each parallel side 109 includes the half bridge tab 125 that aligns with a corresponding offset half bridge tab 125A, 125B of the adjacent panels 100A, 100B such that a full bridge tab is formed between adjacent panels 100A, 100B. Each of the half tabs 125 includes a through-hole 126. It is further appreciated that the half tabs 125, 125A, 125B are typically offset with respect to adjacent half-bridge tabs 125, 125A, 125B, so that each tab 125, 125A, 125B can properly be aligned side by side with a corresponding tab 125, 125A, 125B. Correspondingly, each of the half-bridge tabs have through-holes 126, 126A, 126B that allow the effective full bridges to include two through-holes each for screwing into joists. In general, two of the through-holes 126, 126A, 126B are necessary in order to correspondingly affix and secure either side of the apparatuses 100, 100A, 100B to the joists.

It is further appreciated that a corresponding channel 110A, 110B is formed when adjacent panels are aligned, the channels 110A, 110B having a corresponding width d, as described above. Therefore, it is appreciated that half-bridge tabs 125, 125A, 125B typically have a corresponding width d, and are disposed at a depth within the corresponding channels 110, 110A, 110B at a depth D.

FIG. 4 illustrates a top view of an embodiment of decking panel apparatus 100 installed on deck joists 300. As described above, the apparatus 100 includes a plurality of bride tabs 115 having through-holes into which screws are affixed for interconnection with the deck joists 300. It is generally appreciated that joist spacing is standard in the industry. Therefore, the location of bridge tab spacing can be predetermined such that the bridge tabs 115 can be properly aligned with joists 300.

Referring still to FIG. 4 and also to FIG. 2, as described above, the sides 109 can be tapered from the top surface 106 to the bottom surface 106 terminating at shelf 111. As such, shelf 111 is not typically visible from the top view as illustrated in FIG. 4. However, it is appreciated that half bridge tabs 125 having through-holes 126 also align with joists 300 for affixation of the apparatus 100. As further described above and in particular with respect to FIG. 3, adjacent apparatuses 100A, 100B can be affixed to joists 300 adjacent apparatus 100 and correspondingly affixed via through-holes.

Similarly, in alternate embodiments as described above, once a first apparatus 100 is affixed to joists 300, fasteners 200 can be inserted into slots 130 and affixed to joists via through-holes 205. Subsequently, adjacent apparatuses can be affixed via respective bridge-tabs are through-holes.

FIG. 5 illustrates a top view of an embodiment of installed decking panel apparatuses 100 installed in various patterns. It is therefore appreciated that it is contemplated in other embodiments that various patterns are possible within the scope of the embodiments described above.

FIG. 6 illustrates a top view of an embodiment of installed decking panel apparatuses 100 forming circular patterns. Therefore, it is appreciated that the embodiments described above can advantageously be modified to several different integral patterns and shapes depending on the desired implementation and aesthetic effects.

It is appreciated that the embodiments herein can be formed of a variety of materials including but not limited to solid polyethylene, polypropylene, poly vinyl chloride (PVC) and the like. Composite can also be used.

The foregoing description and drawings comprise illustrative embodiments of the present invention. Having thus described exemplary embodiments of the present invention, it should be noted by those skilled in the art that the within disclosures are exemplary only, and that various other alternatives, adaptations, and modifications may be made within the scope of the present invention. Merely listing or numbering the steps of a method in a certain order does not constitute any limitation on the order of the steps of that method. Many modifications and other embodiments of the invention will come to mind to one skilled in the art to which this invention pertains having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Although specific terms may be employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation. Accordingly, the present invention is not limited to the specific embodiments illustrated herein, but is limited only by the following claims. 

1. A decking panel apparatus, comprising: a planar body having an upper surface and a lower surface; one or more elongated channels, each channel having an elongated through slot along a portion of the channel; and a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels.
 2. The apparatus as claimed in claim 1 wherein the parallel sides parallel to the channels have a profile that tapers from the upper surface toward the lower surface.
 3. The apparatus as claimed in claim 2 further comprising a half bridge tab adjacent the perpendicular sides.
 4. The apparatus as claimed in claim 3 further comprising a through-hole disposed on the bridge tabs.
 5. The apparatus as claimed in claim 3 further comprising a through-hole disposed on the half bridge tabs.
 6. The apparatus as claimed in claim 1 wherein the parallel sides include an elongated slot adjacent the lower surface.
 7. The apparatus as claimed in 2 wherein the parallel side taper from the upper surface to the lower surface and terminate in a shelf.
 8. The apparatus as claimed in claim 1 wherein the parallel sides parallel to the channels are disposed generally vertical to the upper and lower surfaces.
 9. The apparatus as claimed in claim 8 further comprising an elongated slot disposed along parallel sides, the elongated slot being parallel to the channels.
 10. The apparatus as claimed in claim 9 further comprising a fastener having a head and shaft for disposition into the elongated slot.
 11. A decking panel system, comprising: one or more adjacently placed panels, the panels each comprising: a planar body having an upper surface and a lower surface; one or more elongated channels, each channel having an elongated through slot along a portion of the channel; a bridge tab on either side of each channel and recessed into the channel by a distance, wherein the body includes two parallel sides that are perpendicular to the channels and two parallel sides that are parallel to the channels; and means for coupling to an adjacent decking panel and disposed adjacent the perpendicular sides.
 12. The system as claimed in claim 11 wherein the means for coupling to an adjacent decking panel, comprises a half bridge tab adjacent the perpendicular sides, wherein the half bridge tabs of adjacent panels align with another when the panels are placed side by side, thereby simulating a bridge tab.
 13. The system as claimed in claim 11 wherein the means for coupling to an adjacent decking panel, comprises: an elongated slot disposed along parallel sides; and a fastener disposed in the elongated slot.
 14. The system as claimed in claim 13 wherein the fastener comprises: a head; and a shaft connected to the head, wherein the shaft and head for a T-configuration and wherein a portion of the head is disposed within the elongated slot.
 15. A decking panel kit, comprising: a decking panel apparatus, including: elongated slots and boards in a parallel arrangement simulating a deck pattern; and bridge tabs disposed within the slots and between adjacent boards connecting boards to one another.
 16. The kit as claimed in claim 15 further comprising means for coupling adjacent panels to one another.
 17. The kit as claimed in claim 16 wherein the means for coupling adjacent panels comprises half bridge tabs disposed on sides of the decking panel apparatus.
 18. The kit as claimed in claim 16 wherein the means for coupling adjacent panels comprises: an elongated slot disposed along a side of the decking panel apparatus; and a fastener for interconnection to the elongated slot and to an elongated slot on an adjacent panel and for interconnection to a deck joist.
 19. The apparatus as claimed in claim 18 wherein the fastener connects to the elongated slots via a head.
 20. The apparatus as claimed in claim 19 wherein the fastener connects to the deck joist via a screw inserted through a through-hole disposed through the head and a shaft connected to the head. 